US9605364B2 - Method for producing a fibrous metal structure by means of weaving - Google Patents

Method for producing a fibrous metal structure by means of weaving Download PDF

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Publication number
US9605364B2
US9605364B2 US13/878,657 US201113878657A US9605364B2 US 9605364 B2 US9605364 B2 US 9605364B2 US 201113878657 A US201113878657 A US 201113878657A US 9605364 B2 US9605364 B2 US 9605364B2
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Prior art keywords
metal
weaving
threads
fibrous structure
production
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US20130186507A1 (en
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Thierry Godon
Bruno Jacques Gérard DAMBRINE
Alain Robert Yves Perroux
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Safran Aircraft Engines SAS
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SNECMA SAS
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Assigned to SAFRAN AIRCRAFT ENGINES reassignment SAFRAN AIRCRAFT ENGINES CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: SNECMA
Assigned to SAFRAN AIRCRAFT ENGINES reassignment SAFRAN AIRCRAFT ENGINES CORRECTIVE ASSIGNMENT TO CORRECT THE COVER SHEET TO REMOVE APPLICATION NOS. 10250419, 10786507, 10786409, 12416418, 12531115, 12996294, 12094637 12416422 PREVIOUSLY RECORDED ON REEL 046479 FRAME 0807. ASSIGNOR(S) HEREBY CONFIRMS THE CHANGE OF NAME. Assignors: SNECMA
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    • D03D15/02—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F27/00—Making wire network, i.e. wire nets
    • B21F27/12—Making special types or portions of network by methods or means specially adapted therefor
    • B21F27/128—Making special types or portions of network by methods or means specially adapted therefor of three-dimensional form by connecting wire networks, e.g. by projecting wires through an insulating layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C11/00—Propellers, e.g. of ducted type; Features common to propellers and rotors for rotorcraft
    • B64C11/16—Blades
    • B64C11/20—Constructional features
    • B64C11/26—Fabricated blades
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/60—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the warp or weft elements other than yarns or threads
    • D03D15/67—Metal wires
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D23/00—General weaving methods not special to the production of any particular woven fabric or the use of any particular loom; Weaves not provided for in any other single group
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D25/00—Woven fabrics not otherwise provided for
    • D03D25/005—Three-dimensional woven fabrics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/14—Form or construction
    • F01D5/147—Construction, i.e. structural features, e.g. of weight-saving hollow blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/02—Selection of particular materials
    • F04D29/023—Selection of particular materials especially adapted for elastic fluid pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D29/00—Details, component parts, or accessories
    • F04D29/26—Rotors specially for elastic fluids
    • F04D29/32—Rotors specially for elastic fluids for axial flow pumps
    • F04D29/321—Rotors specially for elastic fluids for axial flow pumps for axial flow compressors
    • F04D29/324—Blades
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2101/00—Inorganic fibres
    • D10B2101/20—Metallic fibres
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2220/00—Application
    • F05D2220/30—Application in turbines
    • F05D2220/36—Application in turbines specially adapted for the fan of turbofan engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/20—Rotors
    • F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05D2240/303—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the leading edge of a rotor blade
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/13—Refractory metals, i.e. Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W
    • F05D2300/133—Titanium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/22—Non-oxide ceramics
    • F05D2300/226—Carbides
    • F05D2300/2261—Carbides of silicon
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/614—Fibres or filaments
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
    • Y02T50/66—
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/4932—Turbomachine making
    • Y10T29/49321—Assembling individual fluid flow interacting members, e.g., blades, vanes, buckets, on rotary support member

Definitions

  • the present invention relates to a method of producing a fibrous metal structure by means of weaving permitting the production of a solid part, such as for example a metal reinforcement for a turbine engine blade.
  • the invention relates to a method of production by weaving that permits the production of a metal reinforcement of the leading edge of a turbine engine blade.
  • the field of the invention is that of turbine engines and more particularly that of fan blades, made of composite or metal material, of a turbine engine and whereof the leading edge comprises a metal structural reinforcement.
  • the invention also applies to the production of a metal reinforcement intended to reinforce a leading edge or a trailing edge of any kind of turbine engine, terrestrial or aeronautic, and in particular a turbine engine of a helicopter or an aircraft turbojet engine, but also open rotor propellers.
  • the invention also applies to the production of any solid parts having a complex geometrical shape.
  • leading edge corresponds to the front part of an aerodynamic profile which faces the air flow and which divides the air flow into a lower-surface air flow and an upper-surface air flow.
  • the trailing edge corresponds to the rear part of an aerodynamic profile where the lower-face and upper-face flows are united.
  • the turbine engine blades and in particular the fan blades, undergo considerable mechanical stresses, associated in particular with the rotational speed, and have to comply with strict conditions concerning weight and space requirement.
  • the metal structural reinforcement protects the leading edge of the composite blade by preventing risks of delamination, fibre rupture or damage due to fibre/matrix de-cohesion.
  • a turbine engine blade comprises an aerodynamic surface extending, in a first direction, between a leading edge and a trailing edge and, in a second direction essentially perpendicular to the first direction, between a foot and a head of the blade.
  • the metal structural reinforcement assumes the shape of the leading edge of the aerodynamic surface of the blade and extends in the first direction beyond the leading edge of the aerodynamic surface of the blade assuming the shape of the profile of the lower face and the upper face of the blade and in the second direction between the foot and the head of the blade.
  • the metal structural reinforcement is a metal part made of titanium produced entirely by milling from a block of material.
  • the metal reinforcement of a leading edge of a blade is a part that is complex to produce, requiring numerous complex reworking and tooling operations involving high production costs.
  • the weaving of the fibrous structure is carried out by means of weaving with a plurality of metal warp threads and weft threads, wherein the diameter of the threads is of the order of several tens of millimeters, typically between 0.1 mm and 0.3 mm.
  • the fibrous structure thus obtained by weaving is a plane relatively rigid structure which has to be deformed to obtain a preformed fibrous structure so as to permit its introduction into a shaping tool.
  • the fibrous structure is woven with threads based on titanium which are difficult to shape, especially on account of the high elastic limit of titanium.
  • the fibrous structure is deformed by means of a specific tool, such as a bending press, before it is put place in the tool.
  • the size of the fibrous structure to be preformed is therefore dependent on the dimensions of the bending press.
  • the weaving dimensions of the fibrous structures are directly limited by the capacity of the bending press available on site.
  • the invention aims to solve the aforementioned problems by proposing a method of weaving making it possible to obtain fibrous structures having large dimensions and not being dependent on the capacity of the available deformation tool.
  • the invention proposes a method of production of a fibrous metal structure by means of weaving with metal weft threads and metal warp threads, characterised in that it comprises a step of weaving said fibrous structure by successive weaving of metal clasps acting as weft threads, said weaving being carried out by the introduction of each of the arms of each of said metal clasps into at least one shed, each shed being formed by two warp threads.
  • Clasp is understood to mean a curved or bent metal part, such as a metal wire, comprising two end arms connected by a joining element in such a way as to form, for example, an essentially U-shaped or V-shaped part.
  • Shed is understood to mean a space formed by two warp threads permitting the introduction of a weft thread.
  • the invention it is possible in a straightforward manner to produce a fibrous structure of large size, the shape whereof is provided during the weaving step by the shape of the clasps acting as weft threads.
  • the method according to the invention makes it possible to carry out weaving of a three-dimensional fibrous structure.
  • the weaving of each of the arms of the clasp into a shed of two warp threads is carried out into different weaving planes.
  • These weaving planes can be parallel or not, the arrangement of the weaving planes of the two arms depending on the shape of the clasp.
  • the method according to the invention thus makes it possible to eliminate an independent step for deformation of the fibrous structure by means of a relatively costly specific tool which, by its dimensions, limits the dimensions of the fibrous structure.
  • the preform of the fibrous structure is provided by the weaving step in itself; the method does not therefore require a subsequent step for deformation of the fibrous structure by cold and/or hot forging with a tool, such as a bending press, in order to impose a particular angle on the fibrous structure.
  • a tool such as a bending press
  • the method of producing a fibrous metal structure according to the invention can also comprise one or more of the following features, considered individually or in any technically possible combinations:
  • the subject-matter of the invention is also a method of producing a solid part, characterised in that it comprises:
  • Said solid part is advantageously a metal reinforcement of the leading edge or trailing edge of the fan blade of a turbine engine.
  • Said solid part is advantageously a metal reinforcement of a propeller.
  • the subject-matter of the invention is also a fibrous structure produced by the method of production according to the invention, characterised in that it is formed by a plurality of woven warp threads and a plurality of woven weft threads, the weft threads being formed by preformed metal clasps.
  • Said plurality of warp threads and said plurality of weft threads are advantageously metal threads based on titanium and/or SiC-titanium threads and/or SiC-boron threads and/or SiC—SiC threads.
  • FIG. 1 is a side view of a blade comprising a metal structural reinforcement of a leading edge obtained from a fibrous structure by means of the method of production according to the invention
  • FIG. 2 is a partial cross-sectional view of FIG. 1 in a cross-sectional plane AA;
  • FIG. 3 is a block diagram showing the main steps for the production of a fibrous metal structure of the method according to the invention, for example for producing a metal structural reinforcement of the leading edge of a turbine engine blade;
  • FIG. 4 illustrates a partial view of the fibrous structure during the first step of the method of production according to the invention
  • FIG. 5 illustrates a partial view of the fibrous structure during the second step of the method of production according to the invention
  • FIG. 6 illustrates diagrammatically a side view of a portion of the fibrous structure during the third step of the method of production according to the invention
  • FIG. 7 illustrates diagrammatically a side view of the fibrous structure illustrated in FIG. 6 through an axis B-B;
  • FIG. 8 illustrates a perspective partial view of the final fibrous structure obtained by the method of production according to the invention.
  • FIG. 1 is a side view of a blade comprising a metal structural reinforcement of a leading edge obtained by means of the method of production according to the invention.
  • Illustrated blade 10 is for example a mobile fan blade of a turbine engine (not represented).
  • Blade 10 comprises an aerodynamic surface 12 extending in a first axial direction 14 between a leading edge 16 and a trailing edge 18 and in a second radial direction 20 essentially perpendicular to first direction 14 between a foot 22 and a head 24 .
  • Aerodynamic surface 12 forms an upper surface 13 and a lower surface 11 of blade 10 , only upper surface 13 of blade 10 being represented in FIG. 1 .
  • Lower surface 11 and upper surface 13 form the lateral faces of blade 10 which connect leading edge 16 to trailing edge 18 of blade 10 .
  • blade 10 is a composite blade typically obtained by shaping a woven fibrous texture.
  • the composite material used can comprise an assembly of woven carbon fibres and a resin matrix, the assembly being formed by moulding by means of a resin injection process of the RTM type (standing for “Resin Transfer Molding”) or the VARRTM type (standing for Vacuum Resin Transfer Molding).
  • Blade 10 comprises a metal structural reinforcement 30 glued at its leading edge 16 and which extends both in first direction 14 beyond leading edge 16 of aerodynamic surface 12 of blade 10 and in second direction 20 between foot 22 and head 24 of the blade.
  • structural reinforcement 30 assumes the shape of leading edge 16 of aerodynamic surface 12 of blade 10 which it extends to form a leading edge 31 , so-called leading edge of the reinforcement.
  • structural reinforcement 30 is a monobloc part having an essentially V-shaped section comprising a base 39 forming leading edge 31 and extended by two lateral sides 35 and 37 respectively assuming the shape of lower surface 11 and upper surface 13 of aerodynamic surface 12 of the blade.
  • Sides 35 , 37 have a profile that tapers or thins out in the direction of the trailing edge of the blade.
  • Base 39 has a rounded internal profile 33 capable of assuming the rounded shape of leading edge 16 of blade 10 .
  • Structural reinforcement 30 is metallic and preferably titanium-based. This material in fact has a great capacity for energy absorption due to impacts.
  • the reinforcement is glued on blade 10 by means of glue known to the person skilled in the art, such as for example a cyanoacrylic glue or epoxy glue.
  • the method according to the invention makes it possible to produce in particular a structural reinforcement such as illustrated in FIG. 2 , FIG. 2 illustrating reinforcement 30 in its final state.
  • FIG. 3 represents a block diagram illustrating the main steps of a method of production 200 of a fibrous metal structure 300 making it possible to produce, for example, a metal structural reinforcement 30 of the leading edge of a blade 10 as illustrated in FIGS. 1 and 2 .
  • First step 210 of method of production 200 is a step for cutting a plurality of metal segments 301 from a continuous metal wire, for example coming from a die, whereof the length of each segment 301 is determined as a function of the final piece to be produced.
  • Metal segments 301 thus cut are illustrated in FIG. 1 .
  • Each metal segment 301 can thus have a specific length depending on its location in the mesh of the fibrous structure.
  • the diameter of metal segments 301 can vary depending on the user's requirements and the material thickness needed to produce the part. The determination of the diameter of the segments is made based on a compromise between flexibility of the fibrous structure and the material thickness required in the tool.
  • Second step 220 of method of production 200 is a step for cold forming or shaping of metal segments 301 cut during first step 210 . This second step is illustrated in FIG. 6 .
  • This second step permits the cold shaping (i.e. at ambient temperature) of each rectilinear metal segment 301 by plastic deformation in such a way as to obtain preformed metal segment 301 ′, the geometry whereof is determined as a function of the final part to be produced and in particular as a function of the shape of the compaction tool used to produce the final part.
  • Metal segments 301 ′ are deformed by means of a simple tool which can be operated manually, the individual deformation of each segment not requiring consequent hydraulic means to produce the deformation.
  • the deformation tool is advantageously a conventional deformation tool which can be automated and calibrated both with regard to the final shape of metal segments 301 ′ and the pressing force depending on the user's requirements.
  • metal segments 301 ′ can be deformed individually or in groups formed by a plurality of metal segments.
  • Step 220 for deforming the segments thus makes it possible to change from a metal segment 301 of a rectilinear shape to a preformed metal segment 301 ′ in the form of a clasp comprising two essentially rectilinear arms 302 and 303 connected to one another by a joining element 304 having undergone at least one deformation.
  • the lengths of arms 302 and 303 can be different for one and the same clasp.
  • Metal segment 301 can also be entirely or partially crushed (for example by a local thickness restriction) or be obtained from a profile that is not circular, but of a square, rectangular, hexagonal type, etc.
  • segments 301 ′ are advantageously bent in a U-shaped or V-shape.
  • Third step 230 of method of production 200 is a step for three-dimensional weaving of a fibrous structure 100 such as illustrated in FIGS. 6, 7 and 8 .
  • FIG. 6 illustrates diagrammatically a side view of a portion of fibrous structure 100 obtained by weaving metal segments preformed in the second step.
  • FIG. 7 illustrates diagrammatically a side view of fibrous structure 100 through axis B-B represented in FIG. 7 .
  • FIG. 8 is a perspective view of a portion of fibrous structure 100 obtained by method of production 200 according to the invention.
  • Weaving step 230 makes it possible to produce one or more fibrous metal structure(s) 100 in three dimensions so as to produce the final part.
  • fibrous structure 100 is formed by a plurality of “warp threads” and “weft threads”, preformed metal segments 301 ′ acting as weft threads in our example of embodiment.
  • Weaving step 230 is carried out by successive weaving of each preformed metal segment 301 ′ acting as a weft thread into sheds formed by two warp threads.
  • the weaving is carried out by introducing each of arms 302 and 303 of each preformed metal segment 301 ′ into at least one shed 305 , 306 formed by two warp threads.
  • Shed is understood to mean a space formed by two warp threads permitting the introduction of a weft thread.
  • Weaving step 230 is carried out by means of a weaving tool of the weaving loom type comprising means capable of forming at least two separate sheds 305 , 306 opening and closing simultaneously in such a way that the two arms 302 , 303 of each preformed metal segment 301 ′ are woven simultaneously into at least two different sheds 305 , 306 .
  • each metal segment 301 ′ is woven by the introduction of each of its arms into at least one shed 305 , 306 in such a way as to form fibrous structure 100 .
  • Each preformed metal segment 301 ′ is inserted into sheds 306 , 307 by means, for example, of a fork supporting preformed metal segment 301 ′ and positioning it in the corresponding sheds.
  • the weaving patterns of fibrous structure 100 are conventionally weaving patterns used for example in the area of weaving composite fibres, such as for example weaving patterns of the twill, taffeta, satin type or the weaving patterns described in patent application EP1526285, except that the weft thread is a preformed thread and is not rectilinear.
  • the metal segments are chiefly titanium-based threads. However, it is possible to incorporate in the weaving metal segments based on silicon carbide and titanium (SiC—Ti), threads coated with boron (SiC-boron thread), or with silicon carbide (SiC—SiC thread).
  • an SiC—Ti or SiC/Ti fibre denotes, for the person skilled in the art, an SiC fibre coated with a titanium-based alloy.
  • Metal segments 301 , 301 ′ essentially have a diameter varying between 0.1 mm and 5 mm.
  • Fibrous structure 100 is then compacted in a shaping tool by hot isostatic pressing (HIP for Hot Isostatic Pressing in English).
  • HIP Hot Isostatic Pressing in English
  • Hot isostatic pressing is a very widely used and known production process for reducing the porosity of metals and influencing the density of numerous metals, such as ceramics.
  • the isostatic pressing process also makes it possible to improve, amongst other things, the mechanical properties and usability of materials.
  • the isostatic pressing is carried out at high temperature (conventionally between 400° C. and 1400° C., and of the order of 1000° C. for titanium) and at isostatic pressure.
  • the application of the heat combined with the internal pressure eliminates the hollow spaces in fibrous structure 100 , as well as the microporosities by means of a combination of plastic deformation, plastic flow and diffusion welding in such a way as to form the final part.
  • the final part comprises the internal and external profiles of metal reinforcement 30 .
  • the produced final part is then removed from the shaping tool.
  • the isostatic pressing step is carried out under vacuum, advantageously under secondary vacuum, either in a welded tool in which the secondary vacuum is produced, or in an autoclave bag, the choice of the process depending on the number of parts to be produced.
  • the secondary vacuum makes it possible to avoid the presence of oxygen in the tool and in the fibrous structure during the step of isostatic pressing of the titanium.
  • the tool is produced in a mechanical alloy, a so-called super-alloy or high-performance alloy.
  • the isostatic pressing can include in advance a step for cleaning, degreasing and/or chemical attack of the fibrous structure so as to eliminate residual impurities of the fibrous structure.
  • the step for cleaning out impurities is advantageously carried out by immersion of the fibrous assembly in a bath of cleaning agent or chemical agent.
  • the part after compaction may require finishing and reworking operations by machining so as to produce reinforcement 30 .
  • These reworking operations can include:
  • the present invention has been described chiefly with the use of titanium-based metal segments to produce the fibrous structure; however, the method of production is also applicable with any kind of metal material having properties that permit super-plastic shaping and/or diffusion welding.
  • the invention has been described in particular for the production of a fibrous structure for the production of a metal reinforcement of a composite turbine engine blade; however, the invention is also applicable to the production of a fibrous structure for the production of a metal reinforcement of a metal turbine engine blade, for the production of a metal reinforcement of a leading edge of a turbine engine blade, for the production of a metal reinforcement of a propeller.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Materials Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Woven Fabrics (AREA)
  • Powder Metallurgy (AREA)
US13/878,657 2010-10-11 2011-10-10 Method for producing a fibrous metal structure by means of weaving Active 2033-06-12 US9605364B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR1058237A FR2965824B1 (fr) 2010-10-11 2010-10-11 Procede de fabrication d'une structure fibreuse metallique par tissage
FR1058237 2010-10-11
PCT/FR2011/052361 WO2012049414A2 (fr) 2010-10-11 2011-10-10 Procede de fabrication d'une structure fibreuse metallique par tissage

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CN (1) CN103154343B (zh)
BR (1) BR112013008739B1 (zh)
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FR (1) FR2965824B1 (zh)
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Cited By (1)

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US10815795B2 (en) 2018-12-20 2020-10-27 General Electric Company Pre-tension and retention structure for composite fan blade

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FR2970715B1 (fr) * 2011-01-21 2014-10-17 Snecma Structure fibreuse tissee multicouches ayant une partie tubulaire creuse, procede de fabrication et piece composite la comportant
RU2570254C2 (ru) 2011-03-01 2015-12-10 Снекма Способ изготовления металлической части, такой как усиление лопатки турбинного двигателя
WO2012117202A1 (fr) * 2011-03-01 2012-09-07 Snecma Procede de realisation d'une piece metallique telle qu'un renfort d'aube de turbomachine
WO2015034612A1 (en) * 2013-09-09 2015-03-12 United Technologies Corporation Fan blades and manufacture methods
WO2015069335A2 (en) * 2013-09-09 2015-05-14 United Technologies Corporation Fan blades and manufacture methods
GB201419412D0 (en) * 2014-10-31 2014-12-17 Rolls Royce Plc Rotary device
FR3041684B1 (fr) * 2015-09-28 2021-12-10 Snecma Aube comprenant un bouclier de bord d'attaque et procede de fabrication de l'aube
CN110344887B (zh) * 2018-04-03 2022-02-18 中国航发商用航空发动机有限责任公司 混合材料风扇叶片及其制备方法
CN112453834A (zh) * 2020-11-19 2021-03-09 中国航空制造技术研究院 复杂型面钛合金零件结构的制备方法

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Publication number Priority date Publication date Assignee Title
US10815795B2 (en) 2018-12-20 2020-10-27 General Electric Company Pre-tension and retention structure for composite fan blade

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EP2627809B1 (fr) 2019-07-17
RU2013120969A (ru) 2014-11-20
CA2813887A1 (fr) 2012-04-19
EP2627809A2 (fr) 2013-08-21
US20130186507A1 (en) 2013-07-25
CA2813887C (fr) 2018-06-26
WO2012049414A3 (fr) 2012-08-30
WO2012049414A2 (fr) 2012-04-19
BR112013008739A2 (pt) 2016-06-28
CN103154343A (zh) 2013-06-12
BR112013008739B1 (pt) 2020-07-07
RU2588842C2 (ru) 2016-07-10
FR2965824B1 (fr) 2013-11-15
FR2965824A1 (fr) 2012-04-13
CN103154343B (zh) 2016-07-06

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